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New power plant generates electricity using hot waste gas from cement production

World Cement,

Südbayerische Portland Zementwerk Gebr. Wiesböck & Co. GmbH, Germany, is constructing the first German power plant to use hot waste gas from cement production to generate electricity. A consortium of the Siemens Industry Solutions Division and Kawasaki Plant Systems Ltd was commissioned to set up the new plant with a waste heat recovery system. Upon completion in April 2012, the plant will cover one third of the cement works' power requirements. 

The new power plant at the cement works in Rohrdorf will use the hot waste gas from the rotary kiln and the clinker cooler, as well as the residual heat from the chimney, to generate electricity. The power plant is sized to include the future waste heat from the chloride bypass. This innovative, highly efficient and environmentally friendly project is being supported by the Federal Ministry for the Environment within the framework of its environmental innovation program. With the construction of a new raw mill and a dedusting facility, the cement works in Rohdorf has already made an important contribution to climate protection.

Kawasaki Plant Systems Ltd and Siemens formed a consortium to construct the plant in order to keep responsibility for the water/steam cycle with a single party. Beforehand, all possible heat sources in the production facility were analysed and evaluated in close cooperation with Portland

Zementwerk GmbH. The cement plant in Rohrdorf is attending to planning and execution of all civil works, steel construction and piping, along with integration into the existing production facility. Siemens is supplying the electrical equipment and instrumentation and control, as well as the steam turbine and the generator. Supervision of construction and commissioning are also comprised in the Siemens contract. Kawasaki is providing the overall plant design and engineering for the water/steam cycle; the company will supply the pressure parts of the boiler, the feed water preheater on the clinker cooler and the air condenser for the steam turbine. The waste heat recovery boiler features horizontal gas passage.

The new power plant, with a capacity of 6.8 MW, will generate some 50 000 MW hours of electrical energy per annum. That is equivalent to the power consumption of 34 600 people or 16 400 households. The generation of power from this industrial waste heat will also eliminate some 31 500 t of CO2/y.

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